PFI Standard ES-16

|Denotes Revision (Revised December 2013)

ACCESS HOLES, BOSSES AND PLUGS

FOR RADIOGRAPHIC INSPECTION
OF PIPE WELDS

Prepared by
Pipe Fabrication Institute Engineering Committee

All PFI Standards are advisory only. There is no

agreement to adhere to any PFI Standard and
their use by anyone is entirely voluntary.

Copyright by

PIPE FABRICATION INSTITUTE

Dedicated to Technical Advancements and Standardization in
the Pipe Fabrication Industry
Since 1913
USA CANADA
511 Avenue of America’s, # 601 655, 32nd Avenue, # 201
New York, NY 10011 Lachine, QC H8T 3G6

WEB SITE
http://www.pfi-institute.org

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 PFI Standard ES-16
|Denotes Revision (Revised December 2013)

ACCESS HOLES, BOSSES AND PLUGS

FOR RADIOGRAPHIC INSPECTION OF PIPE WELDS

METRIC CONVERSIONS

The conversion of quantities between systems of units involves a determination of the number of significant digits to
be retained. All conversions depend upon the intended precision of the original quantity and are rounded to the
appropriate accuracy.
Pipe sizes together with applicable wall thickness are not shown with metric equivalents.
The SI (metric) values where included with the customary U.S. values in this Standard are the rounded equivalents of
the U.S. values and are for reference only.

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Metric units were derived utilizing the following conversion factor:

Conversion Factor
_________ _____
inches to 25.4
millimeter

Foreword

Previous versions of this standard provided a simple method for plugging the hole required for inserting a gamma source
into a pipe to allow panoramic radiographic exposures. The original radiographic plug designs, (Figures 1 through 7), have
been used extensively, providing many years of reliable service, and these designs have not changed. Experience has
demonstrated that their time to failure is comparable to the piping systems they were installed in when the systems have
not experienced long term creep damage. Creep is plastic deformation under load that is dependent on stress, time,
temperature, and material. PFI had been alerted to occurrences of plug seal weld failures where the piping system had
experienced significant creep damage. PFI reviewed the reported failures and initiated a research project sponsored by
ASME and PFI and published as STP-PT-050.

The initial study used finite element creep simulation to examine a plug geometry compliant with Figures 2 through 5 of
this standard and then compared the results with a bored out, or thimble-shaped plug used by some high temperature
component manufacturers, using a similar simulation, The results indicate there are no substantial benefits, and possibly a
detrimental impact, to using the bored out plugs. However, the study’s results also indicated that after prolonged service,
for both types of plugs, the stresses initially carried by the plug’s threads are increasingly carried by the circumferential
plug seal welds. In addition to thread corrosion, creep stretches the hole in which the plug is located, possibly increasing
stress on the circumferential plug seal weld. This research was consistent with reported failures of radiographic access port
plugs due to creep.

A subsequent study was initiated to evaluate the use of an integrally reinforced boss compliant with Figures 8 through 11.
The analysis considered grade P91 pipe at temperatures of 900 ˚F and 1150 ˚F using a grade F22 boss in an effort to avoid
PWHT of the plug seal weld after radiographic examination. The boss geometry was designed so that the surface that the
plug seal weld attaches to meets the B31.1 thickness exemption for PWHT. The analysis confirmed that this geometry will
yield a life expectancy comparable to the pipe itself. The analysis also revealed a decrease in service life at 1150 ˚F due to
the dissimilar material interface. For this reason, it is recommended that the use of grade F22 boss on a P91 header be
limited to 1100 ˚F. No other dissimilar material combinations were considered in this analysis.

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 PFI Standard ES-16
|Denotes Revision (Revised December 2013)

1. Scope
This standard covers recommendations for access holes, bosses and plugs for the radiographic inspection of pipe butt
welds where the radiographic source is located on the inside of the pipe. Radiographic access ports should not be used
unless necessary. Since routine double-wall radiography is capable of making high-quality radiographs on pipe that is 5/8”
inch thick or less and NPS 16” inch and smaller, radiographic access ports are unnecessary and should not be specified.
When digital radiography will be used, greater thickness and larger sizes of pipe may be radiographed without resorting to
access ports. Figures 1 through 7 are recommended for applications where temperatures are below the creep range. For
RT bosses used in piping systems that may operate within the creep range, alternative bosses, as provided in Sections 6, 7
& 8 are recommended.

2. Access Hole and Plug

2.1 For pipe wall thickness less than 5/8 in. (16mm) thick, the location and design of the access hole and plug shall be
as shown in Fig. 1 or Fig. 6.

1 1/4"
* 6"(152mm) (32mm)
4"min(102mm)
TAP 1"-8UNC-2B
2 1/4" 1/2" (13mm)
WELD METAL 1/32"(1mm) R.x.020"(1mm)
(57mm)
BUILDUP DEEP IDENT. TOOL
MARK 3/8" (10mm)
NECK 1/4" (6mm) x
5/8" 1/8" (3mm) DEEP
T (16mm)
1"-8UNC-3A 5/8" (16mm)

T = Nominal Wall
* Prefered

FIGURE 1

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 PFI Standard ES-16
|Denotes Revision (Revised December 2013)

2.2 For pipe wall thickness 5/8 in. (16 mm) through 1 3/8 in. (35 mm), the location and design of the access hole and
plug shall be shown in Fig. 2.

1 1/4"
* 6"(152mm) (32mm)
4"min(102mm)
TAP 1"-8UNC-2B
1/2" (13mm)
1/32"(1mm) R.x.020"(1mm)
DEEP IDENT. TOOL
MARK 3/8" (10mm)
NECK 1/4" (6mm) x
T 1/8" (3mm) DEEP
1"-8UNC-3A H

T = Nominal Wall
H = tm (minimum wall)
* Prefered
FIGURE 2

2.3 For pipe wall thickness over 1 3/8 in. (35 mm) through 3 in., (76 mm) the location and design of the access hole
and plug shall be as shown in Fig. 3.

1 1/4"
(32mm)

* 6"(152mm)
4"min(102mm) 1/2" (13mm)
TAP 1"-8UNC-2B 1/32"(1mm) R.x.020"(1mm)
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DEEP IDENT. TOOL

MARK 3/8" (10mm)
NECK 1/4" (6mm) x
1 3/8" 1/8" (3mm) DEEP
(35mm) T
1 1/4"
1"-8UNC-3A (32mm)
H

T = Nominal Wall
H = tm (minimum wall)
* Prefered 13/16"
(21mm)

FIGURE 3

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 PFI Standard ES-16
|Denotes Revision (Revised December 2013)

2.4 For pipe wall thickness over 3 in. (76 mm) through 5 in., (127 mm) the location and design of the access hole and
plug shall be as shown in Fig. 4.

1 3/4"
(44mm)
* 6"(152mm)
4"min(102mm) TAP 1 1/2"-6UNC-2B
1/2" (13mm)
1/32"(1mm) R.x.020"(1mm)
DEEP IDENT. TOOL
MARK 3/8" (10mm)
1 5/8" NECK 1/4" (6mm) x
(41mm) 1/8" (3mm) DEEP
T
1 1/2"
1 1/2"-6UNC-3A (38mm)
H

T = Nominal Wall
H = tm (minimum wall)
* Prefered

1 15/64"
FIGURE 4 (31mm)

2.5 For pipe wall thickness over 5 in., (127 mm) the location and design of the access hole and plug shall be as shown
in Fig. 5.

2 1/4"
(57mm)
* 6"(152mm)
4"min(102mm) TAP 2" - 4½UNC-2B
1/2" (13mm)
1/32"(1mm) R.x.020"(1mm)
DEEP IDENT. TOOL
MARK 3/8" (10mm)
2 1/8" NECK 1/4" (6mm) x
(54mm) 1/8" (3mm) DEEP
T
2" (51mm)
2" - 4½UNC-3A
H

T = Nominal Wall
H = tm (minimum wall)
* Prefered

1 21/32"
FIGURE 5 (42mm)

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 PFI Standard ES-16
|Denotes Revision (Revised December 2013)

3. Radiographic Boss and Plug

3.1 Radiographic boss may be used in lieu of weld build-up (Fig. 1) for wall thicknesses 5/8 in. (16mm) or less to
minimize or eliminate distortion and out-of-roundness. Attachment of the boss and the plug shall be as shown in
Fig. 7.

1 1/4"
(32mm)

TAP 1"-8UNC-2B
1/2" (13mm)
1/32"(1mm) R.x.020"(1mm)
1 3/4" DEEP IDENT. TOOL
(44mm) 1/16" MARK 3/8" (10mm)
(2mm)
NECK 1/4" (6mm) x
1/8" (3mm) DEEP

1" (25mm) 1" (25mm) 1" + T

1"-8UNC-3A (25mm) + T

9/32" (7mm) x 45° 1/16" (2mm) T

13/16"
(21mm)

T = Nominal Wall

FIGURE 6

4. Attachment of the Radiographic Boss and Seal Welding of Access Hole Plug
4.1 Attachment of the radiographic boss and seal welding of the access hole plug shall be as shown in Fig. 7.

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3/8" (10mm) FILLET WELD
(TWO OR MORE PASSES)
3/8" (10mm) FILLET WELD
(TWO OR MORE PASSES)

FULL PENETRATION
WELD 1/4" (6mm) MIN.
FILLET
REINFORCEMENT

1/16" (2mm)
Boss Type Integral Type

FIGURE 7

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 PFI Standard ES-16
|Denotes Revision (Revised December 2013)

5. General Comments
5.1 Upon completion of radiography and acceptance of the weld, a plug shall be inserted to close the access hole and
shall be seal welded to the pipe. Seal weld is not designed or intended to be a pressure retaining weld.

5.2 Plug and boss material selected from acceptable material specifications as listed in the applicable code and
compatible with the pipe material shall be used. Proper consideration shall be given to the integrity of the plug and
boss stock material.

5.3 Plug material designation shall be permanently marked on either the head or the side of each plug.

5.4 The boss material designation shall be permanently marked on the side of each boss.

5.5 The female RT plug threads may extend through the full thickness of the pipe wall.

5.6 It is recommended that the female threads for the plug be chased just prior to installation of the plug when PWHT
has been performed.

6. General Recommendations for Boss and Plugs in Creep Service

6.1 Plant operating and maintenance records should be reviewed to determine if weld repairs have been made to
access hole bosses or plugs. If any threaded connections have been repaired, after long-term operation, this could
indicate a general deterioration of threads.

6.2 Seal welds and the surrounding base metal of suspect items should be dye penetrant or magnetic particle
examined. In the event of cracking, appropriate repairs should be made.

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 PFI Standard ES-16
|Denotes Revision (Revised December 2013)

7. Radiographic Boss and Plug For Creep Service

7.1 Radiographic Boss and Plug for pipe wall thickness to 1 ½” (38mm)
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7.2 Radiographic Boss and Plug for pipe wall thickness 1 ½” (38mm) to 3 ¼” (82.55mm).

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 PFI Standard ES-16
|Denotes Revision (Revised December 2013)

7.3 Radiographic Boss and Plug for pipe walls greater than 3 ¼” (82.55mm).

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8. Attachment of Radiographic Boss and Seal Welding of Access Hole Plug For Creep Service

8.1 Attachment of the radiographic boss and seal welding of the access hole plug shall be as shown in Fig. 11.

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 CURRENT INDEX OF 2014-2015
PFI STANDARDS & TECHNICAL BULLETINS
Engineering and Design
ES02 R13 Method of Dimensioning Piping Assemblies
ES07 R13 Minimum Length and Spacing for Welded Nozzles
ES16 R13 Access Holes, Bosses, and Plugs for Radiographic Inspection of Pipe Welds
ES26 R13 Welded Load Bearing Attachments to Pressure Retaining Piping Materials
ES36 R13 Branch Reinforcement Work Sheets.
ES36 R13 Branch Reinforcement Work Sheets – ELECTRONIC VERSION
ES40 RA10 Method of Dimensioning Grooved Piping Assemblies
ES44 R13 Drafting Practices Standard
Welding and Fabrication
ES01 R10 Internal Machining and Solid Machined Backing Rings For Circumferential Butt Welds
ES21 R10 Internal Machining and Fit-up of GTAW Root Pass Circumferential Butt Welds
ES24 R13 Pipe Bending Methods, Tolerances, Process and Material Requirements
ES35 RA03 Nonsymmetrical Bevels and Joint Configurations for Butt Welds
ES45 R13 Recommended Practice for Local Post-Weld Heat Treatment
ES47 R13 Welding of Internally Clad Piping
ES49 R13 Guidelines for Installation of Integrally Reinforced Branch Connection Fittings
Cleaning, Painting, and Shipping
ES05 R13 Cleaning of Fabricated Piping
ES29 R06 Internal Abrasive Blast Cleaning of Ferritic Piping Materials
ES31 RA04 Standard for Protection of Ends of Fabricated Piping Assemblies
ES34 R03 Temporary Painting/Coating of Fabricated Piping
ES37 RA10 Standard for Loading and Shipping of Piping Assemblies
Quality Control
ES03 R09 Fabricating Tolerances
ES11 R03 Permanent Marking on Piping Materials
ES22 R13 Recommended Practice for Color Coding of Piping Materials.
ES32 R13 Tool Calibration
ES39 RA10 Fabricating Tolerances for Grooved Piping Systems
ES41 RA03 Standard for Material Control and Traceability of Piping Components
ES43 RA13 Standard for Protection of Austenitic Stainless Steel and Nickel Alloy Materials
Examination and Testing
ES04 R13 Hydrostatic Testing of Fabricated Piping
ES20 R13 Wall Thickness Measurement by Ultrasonic Examination
ES27 R10 "Visual Examination" The Purpose, Meaning and Limitation of the Term
ES42 R05 Standard for Positive Material Identification of Piping Components using Portable X-Ray Emission Type Equipment
ES48 R13 Random Examination

Technical Bulletins
TB1 R13 Pressure - Temperature Ratings of Seamless Pipe Used in Power Plant Piping Systems - ELECTRONIC VERSION
TB3 R13 Guidelines Clarifying Relationships and Design Engineering Responsibilities Between Purchasers’ Engineers and Pipe Fabricator or Pipe
Fabricator or Pipe Fabricator Erector
TB5 R13 Information Required for the Bidding of Pipe Fabrication
TB7 R04 Guidelines for Fabrication and Installation of Stainless Steel High Purity Distribution Systems
TB8 R13 Recommended practice for the fabrication of polyvinylidene fluoride (PVDF) piping
TB9 R13 Customary Fitting, Forging, Plate and Bar Materials used with Pipe
ELECTRONIC VERSION

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 “1913 – 2013”

Visit our website www.pfi-institute.org

for;
A complete list of PFI members and available membership

 CHARTER MEMBERS
 CONTRACTOR MEMBERS
 ASSOCIATE MEMBERS
 AFFILIATE MEMBERS
 HONORARY MEMBERS

Associate and Affiliate member contributors

Walter Sperko Sperko Engineering Services, Inc. Greensboro, NC
Thomas Warrelmann Victaulic Company of America Easton, PA
Sheryl Michalak Welding Outlets, Inc. Houston, TX

PFI Standards and Technical Bulletins are published to serve proven needs of the pipe
fabricating industry at the design level and in actual shop operations. Hence, such needs
are continually considered and reviewed by the Engineering Committee of the Pipe
Fabrication Institute to provide recommended procedures, which have been demonstrated
by collective experiences to fulfill requirements in a manner for Code compliance.
However, as the PFI Standards are for minimum requirements the designer or fabricator
always has the option of specifying supplementary conditions in the form of requirements
beyond the scope of the PFI publications.
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